Axial flux electric machine

Abstract

An electric machine is described. The electric machine includes a rotor comprising a rotor disk and a plurality of permanent magnets magnetically coupled to the rotor disk. The plurality of permanent magnets include a substantially flat profile and are aligned in a substantially planar array. The electric machine also includes a stator comprising a solid stator core and a plurality of coils each wound around a coil insulating member. The stator core includes a plurality of stator teeth extending substantially parallel to an axis of rotation of the rotor.

What is claimed is: 
     
       1. An axial flux electric machine comprising:
 an end shield; 
 a housing coupled to said end shield; 
 a stator core positioned within said housing and comprising a plurality of teeth that extend axially from a stator core base, said stator core further comprising a flange extending radially from said stator core; and 
 a stator core retention ring positioned within said housing and coupled between said stator core and said end shield, said stator core retention ring configured to secure said stator core within said housing. 
 
     
     
       2. A machine in accordance with  claim 1 , wherein said stator core retention ring is positioned at least partially around an outer diameter of said stator core. 
     
     
       3. A machine in accordance with  claim 1 , wherein said flange is positioned at least partially between said end shield and said stator core retention ring. 
     
     
       4. A machine in accordance with  claim 1 , wherein said stator core comprises at least one of a soft magnetic alloy (SMA) and a soft magnetic composite (SMC) material. 
     
     
       5. A machine in accordance with  claim 1 , wherein said flange and said stator core retention ring each comprises an alignment feature configured to prevent rotation of said stator core with respect to said end shield. 
     
     
       6. A machine in accordance with  claim 5 , wherein said alignment feature is further configured to align said stator core with respect to said end shield. 
     
     
       7. A machine in accordance with  claim 5 , wherein said alignment features comprise at least one of a protrusion and a corresponding notch. 
     
     
       8. A machine in accordance with  claim 5 , wherein said stator core retention ring further comprises at least one retention ring fastener opening defined therein and said end shield further comprises at least one end shield fastener opening defined therein, wherein said alignment feature is further configured to align said at least one retention ring fastener opening and said at least one end shield fastener opening. 
     
     
       9. A machine in accordance with  claim 8 , further comprising at least one fastener configured to extend through said at least one retention ring fastener opening and at least partially into said at least one end shield fastener opening and to couple said stator core retention ring to said end shield. 
     
     
       10. A machine in accordance with  claim 1 , further comprising at least one stator connection board that includes at least one stator connection board opening defined therein, further comprising at least one fastener, wherein said at least one fastener is configured to extend through said at least one stator connection board opening, said at least one retention ring fastener opening, and at least partially into said at least one end shield fastener opening to couple said at least one stator connection board and said stator core retention ring to said end shield.